Downhole Tool Actuation

ABSTRACT

In one aspect of the invention, a downhole tool string component has at least one end adapted to connect to an adjacent tool sting component and a bore adapted to accommodate a flow of drilling fluid. A turbine is disposed within the bore and an actuating assembly is arranged such that a clutch may mechanically connect and disconnect with the turbine.

BACKGROUND OF THE INVENTION

This invention relates to actuating downhole tools, specifically tools for oil, gas, geothermal, and horizontal drilling. Downhole tool actuation is often accomplished by dropping a ball down the bore of the drill string to break shear pins, which, upon breaking, frees a valve to open actuating a tool such as a reamer. Once the pins are broken, the drill string must be removed from the hole to replace them. Other disadvantages, such as an inability to reset the tool while still downhole, are inherent in this type of design.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the present invention, a downhole tool string component has at least one end with an attachment to an adjacent tool string component and a turbine disposed in a drilling mud bore. An actuating assembly is arranged in the bore such that when actuated a clutch mechanically connects the assembly to the turbine and when deactivated the assembly and turbine are mechanically disconnected.

The actuating assembly may move a linear translation mechanism, which may include a sleeve. The sleeve may have at least one port that is adapted to align with a channel formed in a wall of the bore when the sleeve moves. The actuating assembly may control a reamer, a stabilizer blade, a bladder, an in-line vibrator, an indenting member in a drill bit, or combinations thereof.

The actuating assembly may comprise a collar with a guide slot around a cam shaft with a pin or ball extending into the slot. When the collar moves axially, the cam shaft rotates due to the interaction between the pin or ball and the slot. The cam shaft may be in mechanical communication with the shaft and adapted to activate the switch. The cam shaft may be in communication with a switch plate adapted to engage a plurality of gears. The actuating assembly may comprise at least one solenoid adapted to move a translation member in communication with the switching mechanism.

In some embodiments, the actuating assembly comprises a switching mechanism adapted to rotate a gear set in multiple directions.

The clutch may be a centrifugal clutch adapted to rotate with the turbine. The clutch may have at least one spring loaded contact with adapted to connect the clutch to the shaft. The actuating assembly may be triggered by increase in turbine rotational velocity, a decrease in turbine velocity, or a combination thereof. In some embodiments, the clutch may be controlled by a solenoid. The clutch may also be controlled over a wired drill pipe telemetry system, a closed loop system, or combinations thereof.

In another aspect of the present invention, a downhole tool string component comprises at least one end with an attachment to an adjacent tool string component and a drilling mud bore. A turbine is disposed within the bore that is in mechanical communication with a linear actuator that is aligned with a central axis of the tool string component.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective diagram of an embodiment of a drill string suspended in a borehole.

FIG. 2 a is a perspective diagram of an embodiment of a reamer in a tool string.

FIG. 2 b is a cross-sectional diagram of an embodiment of a reamer in a tool string.

FIG. 3 is a cross-sectional diagram of an embodiment of a downhole drill string component.

FIG. 4 is a cross-sectional diagram of an embodiment of a downhole drill string component.

FIG. 5 is a cross-sectional diagram of an embodiment of a downhole drill string component.

FIG. 6 is a perspective diagram of an embodiment of a portion of a downhole drill string component.

FIG. 7 is a perspective diagram of an embodiment of a portion of a downhole drill string component.

FIG. 8 a is a cross-sectional diagram of an embodiment of a downhole drill string component.

FIG. 8 a is a cross-sectional diagram of an embodiment of a downhole drill string component.

FIG. 9 is a cross-sectional diagram of an embodiment of a downhole packer.

FIG. 10 a is a perspective cross section of an embodiment of a downhole drill string component.

FIG. 10 b is a perspective cross section of an embodiment of a downhole drill string component.

FIG. 11 a is a perspective cut-away of an embodiment of a weighted clutch.

FIG. 11 b is a perspective cut-away of an embodiment of a weighted clutch.

FIG. 12 a is a perspective diagram of an embodiment of a downhole drill string component.

FIG. 12 b is a perspective diagram of an embodiment of a downhole drill string component.

FIG. 13 a is a cross-sectional diagram of an embodiment of a drill bit.

FIG. 13 b is a cross-sectional diagram of an embodiment of a drill bit.

FIG. 14 is a cross-sectional diagram of an embodiment of a reamer.

FIG. 15 is a cross-sectional diagram of an embodiment of a stabilizer in a drill string component.

FIG. 16 is a perspective diagram of an embodiment of a vibrator.

FIG. 17 is a perspective diagram of an embodiment of a downhole drill string component.

FIG. 18 a is a perspective diagram of an embodiment of a turbine.

FIG. 18 b is a perspective diagram of an embodiment of a turbine.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

FIG. 1 is a perspective diagram of an embodiment of a drill string 100 suspended by a derrick 108 in a bore hole 102. A drilling assembly 103 is located at the bottom of the bore hole 102 and comprises a drill bit 104. As the drill bit 104 rotates downhole the drill string 100 advances farther into the earth. The drill string 100 may penetrate soft or hard subterranean formations 105. The drilling assembly 103 and/or downhole components may comprise data acquisition devices adapted to gather data. The data may be sent to the surface via a transmission system to a data swivel 106. The data swivel 106 may send the data to the surface equipment. Further, the surface equipment may send data and/or power to downhole tools, the drill bit 104 and/or the drilling assembly 103.

FIG. 2 a is a perspective diagram of an embodiment of a downhole drill string component 201 with a reamer 200. The reamer 200 may be adapted to extend into and retract away from a borehole wall. While against the borehole wall, the reamer 200 may be adapted to enlarge the diameter of the borehole larger than accomplished by the drill bit at the front of the tool string component.

FIG. 2 b is a cross-sectional diagram of an embodiment of a reamer 200. A sleeve 202 located within the bore 204 of the tool sting component 201 may comprise ports 203. The ports 203 may be adapted to divert drilling mud from the bore 204 when aligned with openings 250 formed in the bore wall. The diverted drilling mud may engage a piston 205 located in a chamber 251 otherwise isolated from the bore 204, after which the drilling mud is re-diverted back into the bore 204 of the tool string component 201. As the piston 205 extends, it may push the reamer 200 outward. A ramp formed in the reamer body may cause the reamer 200 to extend radially as an axial force from the piston 205 is applied. The piston 205 and reamer 200 may stay extended by a dynamic force from the flowing drilling mud. The reamer body may be in mechanical communication with a spring 206 or other urging mechanism adapted to push the reamer 200 back into a retracted position in the absence of the dynamic drilling mud force. A reamer that may be compatible with the present invention with some modifications, is disclosed in U.S. Pat. No. 6,732,817 to Smith International, which is herein incorporated by reference for all that it contains.

When the sleeve 202 is moved such that the ports 203 and openings 250 misalign, the dynamic force is cut off and the reamer 200 retracts. In other embodiments, a pause in drilling mud flow may also cause the reamer 200 to retract. The sleeve 202 may be moved to realign and misalign on command to control the position of the reamer 200. In some embodiments, the sleeve 202 is adapted to partially align with the openings 250, allowing a fluid flow less than its maximum potential to engage the piston 205, and extending the reamer 200 less than its maximum diameter.

FIG. 3 is a cross-sectional diagram of an embodiment of a downhole drill string component 201. The drill string component 201 may comprise an actuating assembly 333 adapted to move the sleeve 202 axially. In some embodiments, the actuating assembly is a linear actuator. The drill string component 201 may also comprise a turbine 400 in mechanical communication with the actuation assembly 333 wherein the turbine may be involved in triggering and/or powering the actuation assembly 333. The actuation assembly 333 may engage or disengage a plurality of gears 304, such as a planetary gear system, adapted to move a linear screw member 1004 connected to the sleeve 202.

FIGS. 4 and 5 disclose a turbine located in the drilling component's bore. As drilling mud is passed down the drill string component 201, as indicated by the arrows 402, the drilling mud rotates a turbine 400. The turbine 400 may be connected to a driving gear 410 disposed on the end of a shaft 401 opposing the turbine 400. The turbine 400 may be in mechanical communication with a centrifugal clutch 502 and when rotated, the turbine 400 rotates the centrifugal clutch 502. When rotating fast enough, the centrifugal clutch 502 engages a mount 501 causing the mount to rotate with the turbine. As the mount 501 is rotated, the weights 555 attached to one end of a pivotally attached bracket 300 may be forced outward away from the central axis of the drill string component 201 while the other end of the bracket 300 moves to push down on a collar 503 located below the mount 501. The collar 503 may comprise a guide pin 557 which interacts with a guide slot 558 formed in a cam housing. When the collar 503 is forced axially it may rotate the cam 556. The rotation of the cam 556 may move a switch plate 504 adapted to selectively place the turbine driving gear in contact with a gear set 304. When activated the gear set may transfer torque from the turbine to a linear screw member 1004 attacked to the sleeve 202.

The guide slot may comprise sections that cause the collar to move in a first direction and other sections that cause the collar to move in an opposing direction. The direction of the collar will dictate how the gear engages the gear set. In a preferred embodiment, the gear set is a planetary gear set that may control the direction that the gears rotate. A clockwise or counterclockwise rotation of the plurality of gears may determine the forward or backward axial movement of the linear screw member 1004.

FIG. 6 discloses the switch plate 504 that moves the cam 556 as the collar 503 is advanced axially. The switch plate 504, as shown in this figure, may be positioned such that the driving gear 410 becomes engaged with a first set of gears 666 mounted to the switch plate 504. The engagement of the gears set 304 may rotate a circular rack 567 that drives a secondary gear set 678 adapted to turn a linear screw member 1004. The collar 503 may be in communication with a spring (not shown) adapted to urge the collar 503 back to its original axial position, after the turbine's rotational velocity substantially returns to its original rpm. Thus, disengaging the driving gear from the gear set and leaving the linear screw member in the resulting position.

When the turbine velocity changes again, the clutch will reengage causing the collar 503 to re-interact with the pin in its guide slot. The slot is formed such that it will cause the cam to push driving gear into a position that causes the gear set to retract the linear screw member as shown in FIG. 7. Thus, the sleeve 202 (shown in FIG. 2 b) attached to the linear screw member may be moved to extend the reamer blade or to collapse the reamer assembly.

FIG. 8 a discloses an arrow 601 indicating the drilling mud flow through the drill string 201 which passes through the bore 204 of the drill string 201 because the sleeve 202 and the ports 203 are misaligned blocking entrance to the drilling mud. FIG. 8 b discloses drilling mud partially diverted through the ports 203 within the sleeve 202 into a channel 608 containing the piston 205. The engaged piston 205 moves the reamer 200 outward due to an inclined ramp formed in the blade (discussed in relation to FIG. 2 b).

FIG. 9 discloses a packer 800 that may be activated in a similar manner as the reamer described above.

FIGS. 10 a and 10 b are cross-sectional diagrams disclosing a solenoid activated clutch First and second opposing solenoids 1002, 1003 are in mechanical communication with a translation member 1050 guided by a shaft 401. The shaft is driven by the turbine which rotates a key gear 1099, which is also translatable through the translation member. When activated, either solenoid moves the key gear through the translation mechanism in its respective direction. Depending on the direction, the key gear 1099 will engage either a forward gear 1098 or a reverse gear 1097 which will drive the gear set to either extend or retract the linear screw member as described above. The translation member may comprise a length adapted to abut a barrier to control its travel. The translation member may be biased, spring-loaded, or comprise an urging mechanism adapted to return the member, and therefore the key gear, to an unengaged position in the absence of an activated solenoid.

The solenoid may be energized through either a local or remote power source. A telemetry system, such as provided by wired drill pipe or mud pulse, may provide the input for when to activate which solenoid. In some embodiments, a closed loop system may provide the input from a sensed downhole parameter and control the actuation.

FIGS. 11 a and 11 b disclose a centrifugal clutch 502 which comprises gippers 1100 attached to springs 1101. When rotating fast enough, a centrifugal force may overcome the spring force and move grippers away from the shaft 401. At lower rotational velocities the grippers 1100 bear down on the shaft 401 rotationally locking them together. To engage the centrifugal clutch 502 the flow of the drilling mud may be reduced; and to disengage the flow may be increased.

FIGS. 12 a and 12 b disclose an actuation assembly 333 comprising a turbine 400 connected to a shaft 401. When the centrifugal clutch 502 is engaged, the collar 503 may be pushed forward in a similar manner as described above. In this embodiment, the collar 503 may comprise a ball track 1111 adapted to receive a ball 1112 in communication with a cam 556. As the collar 503 is pushed down, the cam 556 rotates which moves a translation member 1050. Movement of the translation member causes the key gear 1099 to engage with either a forward gear 1098 or reverse gear 1097 as described above, which in turn either advances or retracts the linear screw member.

FIG. 13 a is a cross-sectional diagram of an embodiment of a drill bit 104. The drill bit 104 may comprise an actuating assembly 1500 patterned after those described above. The assembly 1500 may be adapted to axially move an indenting member 1501 towards the cutting surface of the drill bit 104. The indenting member 1501 may be a steerable element, hammer element, penetration limiter, weight-on-bit controller, sensor, probe, or combinations thereof In the embodiment of FIG. 13 b, the indenting member 1501 may be use to control the flow through a nozzle 1506 disposed in the drill bit's face.

FIG. 14 is a cross-sectional diagram of an embodiment of a winged reamer 200, which may be pivotally extended from the diameter of the drill string component 201 by using the linear screw member 1004.

FIG. 15 discloses an actuation mechanism adapted to extend a stabilizer blade 1234. As the ports 203 in the sleeve 202 align with the openings 250, the flow of the drilling mud may be partially diverted to a piston 205 adapted to push a stabilizer 1234 towards a formation.

FIG. 16 discloses an in-line vibrator 1750 disposed within the bore of the drill string component 201. As the shaft 401 rotates due to activation of the clutch, an off-centered mass 1701 is rotated. In-line vibrators may reduce the drilling industry's dependence on jars which violently shake the entire drill string when the drill string gets stuck. An in-line vibrator may successfully free the drill pipe utilizing less energy than the traditional jars, preserving the life of the drill string components and its associated drilling instrumentation. In some embodiments, the use of the in-line vibrator may prevent the drill string from getting stuck in the first place. The distal end 1751 shaft 401 may be supported spider 1752

FIG. 17 discloses a turbine 400 with adjustable blades 1760. A solenoid may be adapted to rotate a cam associated with the blades. By adjusting the blade, the rpm of the turbine maybe changed, and thereby activate or deactivate the centrifugal clutch.

FIGS. 18 a and 18 b disclose an embodiment of a turbine 400. The turbine blades 2000 may be configured to produce higher torque at a lower RPM.

Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention. 

1. A downhole tool string component, comprising: at least one end comprising an attachment to an adjacent tool string component and a drilling mud bore; a turbine disposed within the bore; and an actuating assembly arranged such that when actuated a clutch mechanically connects the assembly to the turbine and when deactivated the assembly and turbine are mechanically disconnected; wherein the actuating assembly moves a linearly translatable sleeve connected to the turbine through a planetary gear system when the actuating assembly is actuated.
 2. (canceled)
 3. The component of claim 1, wherein the sleeve comprises at least one port, wherein the at least one port is adapted to align with a channel formed within a wall of the bore.
 4. The component of claim 1, wherein the actuating assembly comprises a collar with a guide slot disposed around a cam shaft with a pin or ball extending into the slot, wherein when the collar moves axially, the cam shaft rotates due to the interaction between a pin and slot.
 5. The component of claim 4, wherein the cam shaft is in mechanical communication with a shaft and adapted to activate a switch.
 6. The component of claim 4, wherein the cam shaft is in communication with a switch plate adapted to engage a plurality of gears.
 7. The component of claim 1, wherein the clutch is a centrifugal clutch adapted to rotate with the turbine.
 8. The component of claim 6, wherein the clutch comprises at least one spring loaded contact adapted to connect the clutch to a shaft.
 9. The component of claim 1, wherein the actuating assembly comprises a switching mechanism adapted to rotate a gear set in multiple directions.
 10. The component of claim 9, wherein the actuating assembly comprises at least one solenoid adapted to move a translation member in communication with the switching mechanism.
 11. The component of claim 1, wherein the actuating assembly controls a reamer blade associated with the component.
 12. The component of claim 1, wherein the actuating assembly is triggered by an increase in turbine rotational velocity.
 13. The component of claim 1, wherein the actuating assembly is triggered by a decrease in turbine rotational velocity.
 14. The component of claim 1, wherein the actuating mechanism is triggered by an electric signal.
 15. The component of claim 1, wherein the clutch is controlled by a solenoid.
 16. The component of claim 1, wherein the actuating assembly controls a stabilizer blade position.
 17. The component of claim 1, wherein the actuating assembly controls an indenting member in a drill bit.
 18. The component of claim 1, wherein the actuating assembly controls an in-line vibrator.
 19. The component of claim 1, wherein the clutch is controlled over a wired drill pipe.
 20. The component of claim 1, wherein the clutch is controlled through a closed loop system. 